Boom for material transport

ABSTRACT

A foldable boom for conveying an item, said foldable boom being foldable about at least one folding axis, said foldable boom being locatable in a folded stowed position, and moveable to unfolded extended positions; said foldable boom having a near end arranged for pivotal movement about a first horizontal axis located on a turret, said turret being rotatable about a vertical axis; said foldable boom having first conveying apparatus to convey an item therealong, internally within said foldable boom, to a remote end of the foldable boom; wherein said foldable boom is foldable about a folding axis, and a pivoting shuttle equipped with a clamp to releasably hold an item is provided at said folding axis to transfer said item between said first conveying apparatus in boom elements connected about said folding axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/317,779 filed on Jan. 14, 2019, which is a national stage entry under35 C.F.R. 371 of International Application No. PCT/AU2017/050730 filedon Jul. 14, 2017, which claims priority to Australian Patent ApplicationNo. 2016902789 filed on Jul. 15, 2016, the disclosures of which are eachincorporated by reference herein in their entireties.

TECHNICAL FIELD

This invention relates to the conveying of materials, and in particularto a boom for conveying items such as bricks of blocks for use inbuilding.

BACKGROUND ART

The following discussion of the background art is intended to facilitatean understanding of the present invention only. It should be appreciatedthat the discussion is not an acknowledgement or admission that any ofthe material referred to was part of the common general knowledge as atthe priority date of the application.

The inventor previously described a brick laying machine in U.S. Pat.No. 8,166,727. An early prototype brick laying machine, based on thatdescribed in U.S. Pat. No. 8,166,727, and built by the inventor, used achain conveyor with brick holding clamps attached to the chain. Thischain moved from the base of the machine, out along a boom, to thelaying head system. There was a small chain take up mechanism to take upvariations in chain length due to changes in boom geometry. The take upmechanism also allowed some independence between the brick preparationand the laying, however the relatively short length of the take upmechanism meant that the brick preparation and the laying head needed tobe synchronised at least some of the time. This meant that the slowestprocess limited the progress of bricks through the chain. Depending onthe process of the current bricks being laid, either the brickpreparation or the laying head could be the slowest process.

The chain followed a relatively complex path around the boom andtelescopic stick so that as the telescopic stick was extended, the totalchain length remained the same. The chain had brick griping clampsattached to it, so as it wrapped back and forth, it took up considerablespace. If the telescopic stick had many stages, the amount of spacetaken up by the chain and grippers would greatly increase, making theboom and stick assembly larger than is desirable for road transport.

A brick conveyor using flat belts was investigated by the inventor. Thisrequired a substantially level orientation of the boom and telescopicstick and would require other means of moving the bricks vertically toaccommodate for the change in laying height as the structure is builtcourse by course. It was also determined that some cut bricks could bequite short compared to their height and would be unstable iftransported on a flat belt conveyor. In the case of a telescopic stickand boom, dealing with excess belt length would encounter the sameproblems as the chain conveyor.

It is therefore an object of this invention to provide a boom that canbe incorporated into a brick laying machine that could be a road-goingvehicle or in a larger arrangement assembled in situ, and which wouldovercome at least some of the aforementioned problems.

Throughout the specification unless the context requires otherwise, theword “comprise” or variations such as “comprises” or “comprising”, willbe understood to imply the inclusion of a stated integer or group ofintegers but not the exclusion of any other integer or group ofintegers.

In this specification the word “brick” is intended to encompass anybuilding element such as a brick or block, to be placed during theconstruction of a building or wall or the like. Further, it isanticipated that the conveyance of items other than bricks iscontemplated by the invention.

SUMMARY OF INVENTION

A telescoping boom is provided with internal shuttles. The shuttles arefitted with clamps. Each section of boom has a shuttle. The shuttlesmove an object along the boom and pass it from one shuttle to the next.In a preferred arrangement the telescoping boom may be foldable, inorder to provide extended reach with compact stowage.

In accordance with the invention there is provided a telescopingextendable boom for transporting an item, said telescoping extendableboom having a plurality of tubular elements, each of said tubularelements being arranged with a longitudinally extending track insidesaid tubular element, each said longitudinally extending tracksupporting a single shuttle internally inside its tubular element formovement therealong, each said shuttle being equipped with a clamp toselectively clamp a said item, the longitudinally extending tracks ofimmediately connecting telescoping tubular elements being locatedopposite each other, the inner tubular elements inside said telescopingextendable boom being arranged at their near ends to allow theirshuttles to access shuttles of outer tubular elements to enable clampsthereof to transfer a said item therebetween.

Preferably the internal interconnecting telescoping tubular elementshave a void at their near ends opposite said track therein to allowtheir shuttles to access shuttles of outer tubular elements to enablethe clamps thereof to transfer a said item therebetween.

Preferably said telescoping extendable boom includes at its remote end,a pivotable clamp to receive and clamp an item presented by said firstconveying apparatus and particularly said shuttle in said remote endtubular element, said pivotable clamp being pivotally mounted about ahorizontal axis and arranged to present said item for further handling.

Preferably said pivotable clamp is mounted on a linear sliding mountthat has travel extending in a direction linearly through saidhorizontal axis and normal thereto. In this manner said pivotable clampcan reach into the remote end of the telescoping extendable boom toclamp the item, before withdrawing and pivoting about to present theitem for further handling.

Also in accordance with the present invention, there is provided afoldable boom comprising a first boom element in the form of atelescoping extendable boom as hereinbefore described, connected at oneend thereof to a second boom element about a folding axis, said secondboom element also having a longitudinally extending track inside saidsecond boom element supporting a shuttle internally for movementtherealong, wherein said foldable boom is arranged to allow the shuttleof said second boom element and the shuttle in the tubular element atsaid one end of said first boom element, to transfer a said itemtherebetween.

Also in accordance with the present invention there is provided afoldable boom comprising a first boom element and a second boom element,both in the form of a telescoping extendable boom as hereinbeforedescribed, connected at one end of each thereof about a folding axis,wherein said foldable boom is arranged to allow the shuttles in thetubular elements adjacent the folding axis to transfer a said itemtherebetween.

In accordance with a preferred feature of either foldable boom asdescribed above, said track runs along one side of a said boom element,and runs along the same side of an adjacent said boom element connectedabout a said folding axis, and a pivoting shuttle equipped with a clampto hold a said item is provided, pivoting about said folding axis, totransfer said item between shuttles in boom elements connected aboutsaid folding axis.

Preferably said tracks in the aforementioned arrangement run along thelengths of the boom elements on the side opposite to the side where thefolding axis is located.

Preferably the distal telescoping element of one of said first boomelement and said second boom element is smaller in cross sectionaldimensions than the interconnected said tubular element of the otherboom element connected about said folding axis, and said distaltelescoping element is offset relative to said folding axis, tosubstantially centrally align the pathway through said elements at thefolding axis, when the elements are interconnected about said foldingaxis substantially in a straight line.

Preferably, in the shuttle in the interconnected element of said boomelement having the larger cross-sectional dimensions connected aboutsaid folding axis, the clamp thereof includes a deviation in its arms toprovide clearance for the intruding part of the distal telescopingelement of the boom element having the smaller cross-sectionaldimensions, when the elements are interconnected about said folding axissubstantially in a straight line.

In the telescoping elements, the track runs along one side of onetubular element, and runs along an opposite side of an immediateinterconnecting telescoping tubular element, so that the shuttle locatedin the tracks of both tubular elements can locate opposite each other inorder to effect transfer of a said item from the clamp of one shuttle tothe clamp of the other shuttle.

Preferably the internal interconnecting telescoping tubular elementshave a void at their near ends opposite said track therein to allowtheir shuttles to access shuttles of outer tubular elements to enablethe clamps thereof to transfer a said item therebetween.

It will be understood that where there are three or more telescopingtubular elements, the track of the first third and fifth elements willbe located on one side of these tubular elements, while the tracks ofthe second and fourth tubular elements will be located on the oppositeside. The shuttles will run along the length of the elements, at leastas far as they have been telescopingly extended, passing a brick fromone said tubular element to the next, and so on, to effect transfer ofsaid item along the extent of the telescoping part of the boom.

At the folding axis of two boom elements, in an arrangement where thefolding axis extends horizontally on the underside of the boom elements,and a pivoting shuttle pivots about the same folding axis, the tracksrun along the top of the boom elements that are connected about thefolding axis, with the clamps of the shuttles extending down away fromthe tracks. The clamp on the pivoting shuttle extends upward away fromthe folding axis. The tracks of the boom elements that are connectedabout the folding axis overlap in the same manner, so that a shuttlearrives at the folding junction with a said item, the pivoting shuttleclamps the item before the shuttle moves away, the pivoting shuttlepivots as necessary to align with the next boom element and presents theitem to the shuttle in the next boom element, to effect transfer of theitem between the shuttles of the elements at the folding intersection.

It will be understood that with the use of pivoting shuttles at thefolding axis, the orientation of the item relative to the tubularelement will remain the same throughout the folding boom.

A foldable boom may be made with a third boom element and second foldingaxis, and further boom elements connected about further folding axes, inlike manner to that described in relation to the first and second boomelements.

Preferably said foldable boom includes at its remote end, a pivotableclamp to receive and clamp an item presented by said first conveyingapparatus and particularly by said shuttle in said remote end tubularelement, said pivotable clamp being pivotally mounted about a secondhorizontal axis and arranged to present said item for further handling.

Preferably said pivotable clamp is mounted on a linear sliding mountthat has travel extending in a direction linearly through said secondhorizontal axis and normal thereto.

Also in accordance with the invention, there is provided a foldable boomfor conveying an item, said foldable boom being foldable about at leastone folding axis, said foldable boom being locatable in a folded stowedposition, and moveable to unfolded extended positions; said boom havinga near end arranged for pivotal movement about a first horizontal axislocated on a turret, said turret being rotatable about a vertical axis;said foldable boom having first conveying apparatus to convey an itemtherealong, internally within said foldable boom, to a remote end of thefoldable boom; wherein said foldable boom is foldable about a foldingaxis, and a pivoting shuttle equipped with a clamp to releasably hold anitem is provided at said folding axis to transfer said item between saidfirst conveying apparatus in boom elements connected about said foldingaxis.

Preferably said turret has a carousel extending at least partiallyaround said turret near the base thereof, said turret having secondconveying apparatus to convey an item vertically from said carousel tosaid first conveying apparatus, said carousel being rotatable about avertical axis to present an item for access by said second conveyingapparatus.

Preferably said first conveying apparatus comprises at least one shuttleequipped with a clamp to releasably hold an item, said shuttle runningalong a track extending along said boom.

Preferably said foldable boom comprises a first boom element and asecond boom element pivotable about a said folding axis spaced from saidfirst horizontal axis, and parallel therewith.

Preferably each boom element has a said track and at least one saidshuttle.

Preferably at least one of said first boom element and said second boomelement, has further elements arranged in telescoping interconnection.

Preferably both said first boom element and said second boom elementhave further elements arranged in telescoping interconnection.

Preferably said elements are tubular, preferably rectangular or squarein cross-section.

Preferably each element has a said track and one said shuttle arrangedto run along said track, between opposed ends of each said element.

Preferably said tracks are arranged located internally inside saidelements, and said shuttles run inside their respective elements.

Preferably said track runs along one side of a said boom element, andruns along an opposite side of an immediately interconnecting said boomelement, so that the shuttle located in the tracks of both boom elementscan locate opposite each other in order to effect transfer of an itemfrom the clamp of one shuttle to the clamp of the other shuttle.

Preferably said track runs along one side of a said boom element, andruns along the same side of an adjacent said boom element connectedabout a said folding axis, and a pivoting shuttle equipped with a clampto hold an item is provided, pivoting about said folding axis, totransfer an item between shuttles in boom elements connected about saidfolding axis.

Preferably said tracks in the aforementioned arrangement run along thelengths of the boom elements on the side opposite to the side where thefolding axis is located.

Preferably the distal telescoping element of said first boom element issmaller in cross sectional dimensions than the interconnected element ofsaid second boom element connected about said folding axis, and saiddistal telescoping element is offset relative to said folding axis, tosubstantially centrally align the pathway through said elements at thefolding axis, when the elements are interconnected about said foldingaxis substantially in a straight line.

Preferably, in the shuttle in the interconnected element of said secondboom element connected about said folding axis, the clamp there ofincludes a deviation in its arms to provide clearance for the intrudingpart of the distal telescoping element of said first boom element, whenthe elements are interconnected about said folding axis substantially ina straight line.

Alternatively, the distal telescoping element of said first boom elementdiffers in cross sectional dimensions from the interconnected element ofsaid second boom element connected about said folding axis, and thesmaller of the elements is offset relative to said folding axis, tosubstantially centrally align the pathway through said elements at thefolding axis, when the elements are interconnected about said foldingaxis substantially in a straight line. Preferably, in the shuttles inthe boom elements connected about said folding axis, the clamp of theshuttle contained in the boom element having a greater cross-sectionalsize includes a deviation in its arms to provide clearance for theintruding part of the boom element with the lesser cross-sectional size,when the boom elements are interconnected about said folding axissubstantially in a straight line.

Preferably said track runs along one side of one element, and runs alongan opposite side of an immediate interconnecting telescoping element, sothat the shuttle located in the tracks of both elements can locateopposite each other in order to effect transfer of an item from theclamp of one shuttle to the clamp of the other shuttle.

Preferably the internal interconnecting telescoping elements have a voidat their near ends opposite said track therein to allow their shuttlesto access shuttles of outer tubular elements to enable the clampsthereof to transfer an item therebetween.

It will be understood that where there are three or more telescopingelements, the track of the first third and fifth elements will belocated on one side of these elements, while the tracks of the secondand fourth elements will be located on the opposite side. The shuttleswill run along the length of the elements, at least as far as they havebeen telescopingly extended, passing an item from one said element tothe next, and so on, to effect transfer of the item along the extent ofthe telescoping part of the folding boom.

At the folding axis of the two boom elements, the folding axis extendshorizontally on the underside of the boom elements, and a pivotingshuttle pivots about the same folding axis. The tracks run along the topof the boom elements that are connected about the folding axis, with theclamps of the shuttles extending away from the tracks. The clamp on thepivoting shuttle extends away from the location of the folding axis. Thetracks of the boom elements that are connected about the folding axisoverlap in the same manner, so that a shuttle arrives at the foldingjunction with an item, the pivoting shuttle clamps the item before theshuttle moves away, the pivoting shuttle pivots to the extent necessaryto align with the next boom element and presents the item to the shuttlein the next boom element, to effect transfer of the item between theshuttles of the elements at the folding intersection.

Preferably the second conveying apparatus comprises a turret trackextending vertically along said turret, said turret track having ashuttle with a turret shuttle clamp to clamp an item, the shuttleconveying the item from the carousel to the shuttle in the near end ofthe foldable boom.

Preferably the turret supports a rotating mechanism having a clamp toclamp an item presented by said turret shuttle clamp, said rotatingmechanism being provided to rotate an item so that its longitudinalextent aligns with the longitudinal extent of said first boom element,for presentation to a said at least one shuttle.

Preferably the rotating mechanism has a clamp to clamp an item, and ismounted about said first horizontal axis.

Preferably the carousel has a carousel clamp to clamp an item, and inuse, the carousel is rotated to align its clamp with the clamp of theshuttle on the track on the turret, so the item can be transferred fromthe carousel clamp to the turret shuttle clamp, before the turretshuttle transfers the item along the turret track to reach the firstshuttle of the foldable boom. Preferably the carousel clamp can pivotfrom a first position in which the item is deposited on the carousel toa second position in which it presents the brick to the turret shuttleclamp.

Preferably said foldable boom includes at its remote end, a pivotableclamp to receive and clamp an item presented by said first conveyingapparatus, said pivotable clamp being pivotally mounted about a secondhorizontal axis and arranged to present said item for further handling.

Preferably said pivotable clamp is mounted on a linear sliding mountthat has travel extending in a direction linearly through said secondhorizontal axis and normal thereto.

Still further, in accordance with the invention there is provided a boomfor conveying an item, said boom having a near end arranged for pivotalmovement about a first horizontal axis located from a top of a turret,said turret being rotatable about a vertical axis and said boom rotatingtherewith; said boom having first conveying apparatus to convey an itemtherealong, to a remote end of the boom; said turret having a carouselon which said item may be placed, said carousel extending at leastpartially around said turret near the base thereof, said turret havingsecond conveying apparatus to convey said item vertically from saidcarousel to said first conveying apparatus, said carousel beingrotatable about a vertical axis to present said item for access by saidsecond conveying apparatus.

Preferably the carousel has a carousel clamp to clamp said item. In use,the carousel is rotated to align its clamp with the clamp of the shuttleon the turret track, so the brick can be transferred from the carouselclamp to the turret shuttle clamp, before the turret shuttle transfersthe brick along the turret track to reach the first shuttle of thefoldable boom.

Preferably the carousel clamp can pivot from a first position in whichit receives a brick from the programmable brick handling apparatus to asecond position in which it presents the brick to the turret shuttleclamp.

Preferably said first conveying apparatus comprises at least one shuttleequipped with a clamp to releasably hold said item, said shuttle runningalong a track extending along said boom.

Preferably said boom comprises a foldable boom, said foldable boom beingfoldable about at least one folding axis, said foldable boom beinglocatable in a folded stowed position, and moveable to unfolded extendedpositions.

Preferably said foldable boom has a first boom element and a second boomelement pivotable about a folding axis spaced from said first horizontalaxis, and parallel therewith.

Preferably each boom element has a said track and at least one saidshuttle, and each said shuttle is confined for movement along said trackwithin its said boom element.

As an alternative, preferably at least one of said first boom elementand said second boom element, comprises a plurality of elements arrangedin telescoping interconnection. In this arrangement, preferably eachelement of said plurality of elements has a said track and at least onesaid shuttle, and each said shuttle is confined for movement along saidtrack within its said element.

Preferably said first conveying apparatus is configured to convey saiditem internally within said boom.

BRIEF DESCRIPTION OF DRAWINGS

A preferred embodiment of the invention comprising articulatedtelescoping booms incorporated into an automated brick laying machinewill now be explained in the following description made with referenceto the drawings, in which:

FIG. 1 shows a view of the automated brick laying machine 2 with itstruck base 1 with the boom and stick assembly 141 unfolded.

FIG. 2 shows a view of the automated brick laying machine 2 with theboom and stick assembly 141 folded and stowed for driving on a publicroad.

FIG. 3 shows a site plan of the automated brick laying machine 2 set upnear a concrete slab 136 on which the automated brick laying machine 2will build a structure not shown.

FIG. 4 shows a cross section through the first stick 15 and second stick17.

FIG. 5 shows a side view of the brick laying and adhesive applying head32.

FIG. 6 shows a plan view and schematic diagram of the glue applicationsystem 150.

FIG. 7 shows a view of the carousel 48.

FIG. 8 shows a view of the tower 10.

FIG. 9 shows a side view cross section of first boom 12.

FIG. 10 shows an end view cross section of first boom 12.

FIG. 11 shows a view of first boom 12.

FIG. 12 shows a view of shuttle-B1 224.

FIG. 13 shows a side view of shuttle-B1 224.

FIG. 14 shows a view of the tip end of boom 12 and a drive assembly 254.

FIG. 15 shows a view of the tower—first boom (T-B1) rotator 271 and thetower 10 and first boom 12.

FIG. 16 shows a view of the tower—first boom (T-B1) rotator 271.

FIG. 17 shows a view of the second boom 14.

FIG. 18 shows a view of the second end 526 of second boom 14.

FIG. 19 shows a view of the second end 526 of second boom 14.

FIG. 20 shows a cross section side view of the second end 526 of secondboom 14.

FIG. 21 shows a view of the first end 525 of second boom 14.

FIG. 22 shows a view of the rotator-B2-S1 548.

FIG. 23 shows a view of the first stick 15.

FIG. 24 shows a view of the first end 561 of the first stick 15.

FIG. 25 shows a view of the second stick 17.

FIG. 26 shows a view of the first end 598 of the second stick 17.

FIG. 27 shows a view of the second end 599 of the second stick 17.

FIG. 28 shows a view of the third stick 18.

FIG. 29 shows a view of the first end 618 of the third stick 18.

FIG. 30 shows a view of the second end 619 of the third stick 18.

FIG. 31 shows a view of the fourth stick 19.

FIG. 32 shows a view of the first end 637 of the fourth stick 19.

FIG. 33 shows a view of the second end 638 of the fourth stick 19.

FIG. 34 shows a view of the fifth stick 20.

FIG. 35 shows a view of the first end 657 of the fifth stick 20.

FIG. 36 shows a view of the second end 658 of the fifth stick 20.

FIG. 37 shows a view of the second end 658 of the fifth stick 20.

FIG. 38 shows a view of the flipper assembly 687.

FIG. 39 shows a view of the flipper assembly 687.

FIG. 40 shows a view of the brick laying and adhesive applying head 32.

FIG. 41 shows a view of the first boom 12.

FIG. 42 shows a cut-away view of first boom 12 and second boom 14.

FIG. 43 shows a side view of the boom assembly 732 showing internalcable chains.

FIG. 44 shows a side view of the boom assembly boom 732 showing internalcable chains.

FIG. 45 shows a side view of the boom assembly 732 showing internalcable chains.

FIG. 46 shows a view of the stick assembly 744 showing extension cable.

FIG. 47 shows a view of the stick assembly 744 showing retraction cable.

FIG. 48 shows a view of the stick assembly 744 showing retractioncables.

FIG. 49 shows a view of the adhesive applicator 777.

FIG. 50 shows a view of the sliding chain 114.

FIG. 51 shows a view of a hollow chain link 778.

FIG. 52 shows a top view of straight guide 784.

FIGS. 53 and 53A each show a side view of the brick laying and adhesiveapplying head 32 and fifth stick 20.

FIGS. 54A-54E show side views of the foldable boom in various poses.

FIGS. 55A-55G show a sequence of a brick being transferred from thetower 10 to the T-B1 rotator 271 to first boom 12.

FIGS. 56A-56G show a sequence of a brick being transferred from thesecond boom 14 to the B2-S1 rotator 548 to the first stick 15. In theFIGS. 56A to 56G the foldable boom 732 is in a bent pose.

FIGS. 57A-57D show a sequence of a brick being transferred from thesecond boom 14 to the B2-S1 rotator 548 to the first stick 15. In theFIGS. 57A to 57D the foldable boom 732 is in a horizontal pose.

FIGS. 58A-58H, 58J-58N, 58P, and 58Q show a sequence of a brick beingtransferred from the fifth stick 20, to the S5-H flipper 687, havingadhesive applied to the brick, then the brick being transferred to thelaying gripper 44 and being laid.

FIG. 59 shows a close up of the tower shuttle 186 at the top of tower10.

FIG. 60 shows a side view of first boom element 12 and in particular thetransfer of a brick from shuttle-B1 224 to shuttle-B2 531.

FIG. 61 shows a cut away view of part of the brick laying and adhesiveapplying head and showing the mounting of the brick laying head.

FIG. 62 shows a further view of part of the brick laying and adhesiveapplying head and showing the mounting of the brick laying head.

FIG. 63 shows a cut away view of part of the brick laying head.

DESCRIPTION OF EMBODIMENTS

The embodiment is directed toward an articulated telescopinglyextendable boom which is mounted on a truck, forming an automated bricklaying machine. Referring to FIG. 1, a truck 1 supports a brick layingmachine 2 which is mounted on a frame 3 on the chassis (not shown) ofthe truck. The frame 3 provides additional support for the componentryof the brick laying machine 2 beyond the support that would be providedby a typical truck chassis. Individual bricks are placed are placed on acarousel 48, which is located coaxially with a tower 10, at the base ofthe tower 10. The carousel 48 has a gripper mounted thereon whichreceives a brick. The carousel 48 transfers the brick via the tower 10to an articulated (folding about horizontal axis 16) telescoping boomcomprising first boom element in the form of telescopic boom 12, 14 andsecond boom element in the form of telescopic stick 15, 17, 18, 19, 20.Each element 12, 14, 15, 17, 18, 19, 20 of the folding telescoping boomhas a shuttle located inside on a longitudinally extending track in theelement, to transport a brick along the longitudinal extent of theelement. The bricks are moved through the inside of the foldingtelescoping boom by the linearly moving shuttles. The shuttles areequipped with grippers that pass the brick from shuttle to shuttle.Referring to FIG. 4, elements 15 and 17 are shown, showing tracks 25supporting shuttle 26 running along the length of element 17, andshowing tracks 29 supporting shuttle 30 running along the length ofelement 15. Shuttle 26 has jaws 27 and shuttle 30 has jaws 31, whichalternately can grip a brick 298. When the shuttles 27 and 30 arecoincident both sets of jaws 27 and 31 can grip the brick 298 as thebrick is passed from one shuttle 26 to the other shuttle 30.

The end of the boom is fitted with a brick laying and adhesive applyinghead 32. The brick laying and adhesive applying head 32 mounts by pins(not shown) to element 20 of the stick, about an axis 33 which isdisposed horizontally. The poise of the brick laying and adhesiveapplying head 32 about the axis 33 is adjusted by double actinghydraulic ram 35, and is set in use so that the base 811 of a clevis 813of the robotic arm 36 mounts about a horizontal axis, and the trackercomponent 130 is disposed uppermost on the brick laying and adhesiveapplying head 32. The brick laying and adhesive applying head 32 appliesadhesive to the brick and has a robot that lays the brick. Vision andlaser scanning and tracking systems are provided to allow themeasurement of as-built slabs, bricks, the monitoring and adjustment ofthe process and the monitoring of safety zones.

For ease of understanding, headings will be used in the followingdiscussion.

Truck

Referring again to FIG. 1, a vehicle in the form of a rigid body truck 1is used as a base for the automated brick laying machine 2. In thepreferred embodiment the truck 1 is a 8×8, 8×6 or 8×4 rigid body truckmanufactured for example by Volvo, Mercedes, Iveco, MAN, Isuzu or Hino.The truck has a typical driver's cabin 54. In an alternativearrangement, a semi-trailer intended for connection to a prime moverusing a fifth wheel, may be used instead of a rigid body truck. Thebrick laying machine 2 could be mounted on a trailer, but this removesthe convenience of having it truck mounted.

Frame

A frame 3 forming a rigid chassis is mounted to the truck. The frame 3supports a pair of forward legs 4 and a pair of aft legs 5, one of eachpair on each side of the truck. The legs 4 and 5 can telescopicallyextend outwardly, and hydraulic rams then push down feet 6 to providestability to the automated brick laying machine 2. In practice, thehydraulic rams will adjust by positioning the feet 6 so that the frame 3and hence the rigid body truck 1 is positioned horizontally. Thisresults in correct vertical alignment of the vertical axis 9 and thetower 10 which are described hereafter. It follows then, that thiscorrect alignment ensures that, subject to deflection tolerances, theaxis 33 at the end of the element 20 is horizontal, and then withcorrect adjustment of the poise of the brick laying and adhesiveapplying head 32 by the ram 35, the base 811 of a clevis 813 of therobotic arm 36 mounts about a horizontal axis, and the tracker component130 is disposed uppermost on the brick laying and adhesive applying head32.

An enclosure 7 forming an outer body is mounted to the frame 3. Theenclosure 7 provides some weather protection, noise isolation andguarding of moving parts. Referring to FIGS. 1, 2 and 6, the enclosure 7is fitted with a pair of doors 85, 86 that are open when the boom 12 andstick 15 are folded. When the boom 12 and stick 15 are unfolded, the topdoors 85, 86 are closed by moving door 85 to the right 87 and door 86 tothe left 88 to provide a first level of rain protection and noiseisolation.

Carousel

Refer to FIGS. 1, 7 and 8. Referring to FIG. 1, the foldable boom 732can be rotated about a vertical axis 9 to point in any direction awayfrom the truck. Referring to FIGS. 1 and 2, the carousel 48 receivesbricks, one at a time, at a location approximately on the centreline ofthe truck, behind the tower 10, and rotates about a vertical axis 9 toline the bricks up with the rotated folding boom 732.

Referring to FIGS. 7 and 8, the carousel 48 receives a brick from thetransfer robot 64 and passes it to a tower shuttle 186 sliding on thetower 10. Referring to FIG. 7, the carousel 48 is shown in greaterdetail. The carousel has a ring frame 166 which rotates around the tower10 (shown in FIG. 8). The ring frame 166 supports a gripper 74 that cantilt to receive a brick from the transfer robot 64 and then be rotatedto line up with the tower shuttle 186. A detailed description follows.

Referring to FIG. 7, the frame 3 supports a ring guide 167 whichsupports a plurality of rollers 169 that in turn support the ring frame166 which is thus able to rotate about the vertical slewing axis 9. Thering frame 166 supports a bracket 170 that in turn supports an arm 165that rotates about a horizontal rotary axis 77. The arm 165 supports thegripper 74 which has jaws 171, 172 that move toward each other to hold abrick (not shown), or apart to release the brick. The ring frame 166 isrotated about the vertical axis 9 by a servo motor 173 and gearbox 174that drives a pinion 175 engaged with a ring gear 176 fixed to the ringguide 167. The bracket 170 supports a servo motor 177 that drives agearbox 178 which moves the arm 165. The arm 165 supports a servo motor179 and a lead screw 180. The servo motor 179 rotates the lead screw180. The jaws 171, 172 are respectively fitted with lead nuts not shownthat engage with the lead screw 180. The ring frame 166 supports a cableduct 185.

The frame 3 supports a cable guide 181. The cable guide 181 supports acable chain 182. The cable chain 182 is connected at a first end 183 tothe cable guide 181 and is therefore fixed relative to the frame 3. Thecable chain 182 has a second end 184 attached to the cable duct 185.Electric current carrying cables (not shown) that carry power andcontrol signals and sensor signals from the electric control cabinet 82,are routed via the frame 3, through the cable chain 182 to the cableduct 185 and then to the servo motors 173, 177, 179.

The carousel 48 can move the gripper 74 from a pickup position where itreceives a brick, and rotate to a drop off position where it depositsthe brick to the gripper jaws 207, 208 on the tower shuttle 186 (shownon FIG. 8).

Tower

Referring to FIG. 8, the frame 3 supports a slewing ring 11 at its frontend 78, located coaxially with the carousel 48. The slewing ring 11supports a turret in the form of a tower 10. The tower 10 can slew aboutthe vertical axis 9 of the slewing ring 11. The tower 10 supports thefoldable boom 732 (shown in FIG. 1). The tower supports a tower shuttle186 that moves bricks from the carousel 48 at the bottom end of thetower to the foldable boom 732 at the top of the tower 10.

Refer to FIG. 8 and FIG. 59. The tower 10 supports two parallel spacedlinear bearing rails 189, 190. The linear bearing rails 189, 190respectively support four bearing cars 191 and 192 (and others occluded,not shown). The bearing cars 191, 192 support a tower shuttle car 193which in turn supports a gripper 194. The gripper 194 may grasp a brick195. The tower 10 supports a servo motor 196 which drives a toothedpulley 197 that engages with and drives a belt 198 that is connected to,and thereby drives the tower shuttle 186 in a vertical direction. Thetower 10 supports a servo motor 199 that drives a toothed pulley 200that engages and drives a toothed belt 201. Tower 10 supports an upperidler pulley 202. Toothed belt 201 wraps around upper idler pulley 202.The tower shuttle car 193 supports pulleys 203 and 204. The towershuttle car 193 supports a lead screw 206. Leadscrew 206 is connected toa pulley 205. The toothed belt 201 passes around pulley 203, then drivespulley 205 and thus drives the lead screw 206. The belt 201 passesaround pulley 204 and then returns to pulley 200. The tower shuttle car193 slideably supports gripper jaws 207, 208. Gripper jaws 207, 208support lead screw nuts (not shown) that engage leadscrew 206. Leadscrew206 moves jaws 207, 208 toward each other to grip a brick 195, and inthe opposite rotational direction, moves jaws 207, 208 apart to releasethe brick 195.

Refer to FIG. 8. The tower 10 supports a lug 209 with a bore 213 havinga horizontal axis 214, the bore receiving a fastener to connect an endof hydraulic ram 22 (shown in FIG. 1) to control the pose of the firstboom 12. Tower 10 supports clevis plates 210, 211 which have a bore 212with a horizontal axis 13, about which the near end of the first boom isattached for pivoting movement (shown in FIG. 1).

Boom

Refer to FIG. 1. The foldable boom 732 is articulated and telescopic sothat it can position the laying head throughout a large working volume,far from and close to the truck, both low and high so that the layinghead can reach all courses of the structure to be built, both near andfar, low and high. FIG. 54A shows the foldable boom 732 in a folded posefor transport. FIG. 54B shows the foldable boom 732 with the first boom12 raised and the stick assembly 744 vertical. FIG. 54C shows thefoldable boom 732 with the stick assembly 744 horizontal with thetelescopic sections extended. FIG. 54C shows a pose that could be usedto build a multi storey structure. FIG. 54D shows the foldable boom 732with the first boom 12 raised above horizontal and the stick assembly744 lowered slightly below horizontal. FIG. 54E shows the foldable boom732 at its maximum extension with both the first boom 12 horizontal andthe stick assembly 744 horizontal.

The foldable boom 732 allows motion through a big envelope free ofsingularities and poles. A pole is a position within a robot's envelopethat requires rapid rotation of one or more robot joints to maintainconsistent orientation of the end effector, for the end effector to passalong a trajectory that passes through the pole. A singularity is aposition or orientation, or a set of positions and orientations withinthe envelope that cannot be reached, or where the joints of the robotbecome poorly behaved, unstable, or the joint positions are difficult tocalculate. Normal industrial robots typically complete the same taskover and over so that it is possible to design, or alter the trajectoryand robot pose to be free and clear of poles and singularities or topass through a pole with specified rotation of the pole axis. Theautomated brick laying machine however must be able to complete avariety of tasks and any particular structure will require the boom tomove through a large portion of its envelope, thus making a pole andsingularity free working envelope desirable.

Shuttles within each section of the boom transport a brick along theinside of the boom. Shuttles pass a brick from a previous shuttle to thenext. Rotators at each articulated joint of the boom move a brick fromone boom element to the next, passing the brick from a previous adjacentshuttle to the next adjacent shuttle.

The bricks are passed by the shuttles, through the inside of the boom.The bricks are moved through the inside of the boom so that the boomstructure contains the bricks and/or debris, in the unlikely event thata brick, or debris from a brick becomes loose from a shuttle. The boomstructure provides convenient support to mount shuttles opposite eachother. In the present invention within the telescoping elements of theboom and within the telescoping elements of the stick, the shuttles arealternately mounted above or below the brick, so that adjacent shuttlesmay move so that the grippers on the shuttles can both grasp a bricksimultaneously and thereby transfer a brick from one shuttle to thenext, without letting go of the brick. FIG. 60 shows a partial view ofthe inside of the first boom element comprising first boom 12 and secondboom 14, with shuttle-B1 224 gripping a brick 28 from below andshuttle-B2 531 gripping a brick from above. The invention couldalternately be arranged to support the shuttles from the sides of theboom. The invention could alternately be arranged to support theshuttles on the top of the boom, however it would then be desirable tofit an additional enclosure to boom to contain any dropped bricks ordebris and the overall size of the boom would be larger or lessstructurally stiff.

First Boom Element

Referring to FIGS. 1 and 17, the tower 10 pivotally supports a foldableboom on clevis plates 210 and 211 for rotation about horizontal axis 13.The foldable boom comprises a first boom element comprising first boom12 and telescoping second boom 14, and a second boom element comprisingstick assembly 744. First boom 12 can pivot about the horizontal axis 13at the top of the tower 10, and a sliding second boom 14 istelescopically able to slide within the first boom 12.

Second Boom Element

Referring to FIG. 1, the second boom element comprising stick assembly744 is pivotally connected about a horizontal axis 16 by an element inthe form of an articulating first stick 15 to the distal end of thesecond boom 14. The axis 16 is substantially parallel to the horizontalarticulation axis 13 of the first boom.

A sliding second stick 17 is telescopically able to slide within thefirst stick 15. A sliding third stick 18 is telescopically able to slidewithin the second stick 17. A sliding fourth stick 19 is telescopicallyable to slide within the third stick 18. A sliding fifth stick 20 istelescopically able to slide within the fourth stick 19. Collectivelyfirst stick 15, second stick 17, third stick 18, fourth stick 19 andfifth stick 20 form a stick assembly 744 also referred to as the secondboom element.

The number of telescopic booms 12, 14 or sticks 15, 17, 18, 19, 20 couldbe altered without deviating from the inventive concepts described.Collectively the tower 10, booms 12, 14 and sticks 15, 17, 18, 19, 20form a foldable boom 732.

First boom 12 has a first near end 269 and a second distal end 270 shownin FIG. 9. First boom 12 is connected to the tower 10 (shown in FIG. 8)by a pin or pins not shown, through the bore 212, in clevis plates 210and 211, connecting through apertures in first boom located at its nearend 269.

Lug 209 on the tower 10 is connected to the rod end of ram 22 by a pin(not shown). Ram 22 supports a trunnion mount 215 located a shortdistance along the first boom 12 from the near end 269. The trunnionmount 215 provides boom lift lugs 216, 217. The articulated joint 21 ofthe tower 10 to the boom 12 about axis 13 is moved by ram 22 powered byelectricity or hydraulics.

Rotator

Refer to FIG. 15 and FIG. 16. The tower 10 supports a brick rotatingmechanism in the form of T-B1-rotator 271. The T-B1-rotator 271 is usedtransfer a brick from the tower shuttle 186 to the first boom shuttle224 (shown in FIGS. 10, 12 and 55D). FIG. 55A shows the tower shuttle186 holding brick 298. FIG. 55B shows the brick held by the T-B1-rotator271 after receiving it from the tower shuttle 186. FIG. 55C shows theT-B1-rotator 271 moving to align itself with the first boom segment 12.FIG. 55D shows the T-B1-rotator 271 aligned with the first boom segmentand shuttle-B1 224 moving into position under brick 298. It should beunderstood that the boom will not necessarily be horizontal while thisprocess occurs. FIG. 55E shows the shuttle-B1 224 in position under thebrick 298. In this position the shuttle-B1 224 will grip the brick andthe T-B1-rotator 271 will release the brick. FIG. 55F shows the brick298 held by the shuttle-B1 224 moving up the first boom segment 12. FIG.55G shows the T-B1-rotator 271 moving into position to accept anotherbrick from the tower shuttle 186.

A detailed description of the T-B1-rotator follows.

Referring to FIG. 16, T-B1-rotator 271 has a bracket 272 which isfastened to the tower 10 (shown in FIG. 8). Bracket 272 supports aspacer 274 which supports a servo motor 273. Servo motor 273 drives apulley 275. Bracket 272 supports idler pulleys 276, 277 and a bearingreducer 278. Bearing reducer 278 is fitted with an input shaft 279 whichis fitted with a pulley 280 driven by servo motor 273 via an endlesstoothed belt 281 wrapped around pulleys 275, 276, 277 and 280. Arm 282is rotated by bearing reducer 278 about a horizontal axis 290.

Bearing reducer 278 supports an arm 282 having a plate 283 dependingtherefrom at right angles. Plate 283 supports linear guides 284, 285.Linear guides 284, 285 respectively support bearing cars 286, 287 whichrespectively support jaws 288, 289 provided to clamp a brick. Jaws 288,289 respectively are fitted with lead screw nuts 296, 297 shown ashidden lines. Leadscrew nuts 296, 297 engage with leadscrew 293.

Arm 282 supports a servo motor 291 (not shown clearly in FIG. 16, butshown in FIG. 15) which drives a pulley 292. Arm 282 supports aleadscrew 293 fitted with a pulley 294. An endless toothed belt 295 iswrapped around pulleys 292 and 294. Through this arrangement, servomotor 291 drives leadscrew 293 which is engaged with leadscrew nuts 296,294 to move jaws 288, 289 together to grip a brick 298 or apart torelease the brick 298.

As can be seen in the drawings, and particularly in the sequence ofFIGS. 55A to 55G, the brick 298 is transported up the tower 10 with itslongitudinal extent parallel with the vertical axis 9 of the tower 10.The tower shuttle 186 holds the brick 298 in its gripper jaws 207 and208 vertically above the body of the tower shuttle car 193, so that thebrick can be passed within reach of the jaws 288, 289 of T-B1-rotator271. The T-B1-rotator 271 rotates the brick 298 so that its longitudinalextent is aligned with the longitudinal extent of boom 12 (and 14). TheT-B1-rotator 271 rotates about the same horizontal axis 13 as first boom12 is mounted to the tower 10. The location of this horizontal axis 13is such that the shuttle-B1 224 is able to travel under the T-B1-rotator271 to allow the transfer of the brick 298 from T-B1-rotator 271 to theshuttle-B1 224.

First Boom

Refer to FIGS. 9, 10 and 11. Referring to FIG. 9 first boom 12 has boomlift lugs 216, 217 welded thereto. Referring to FIG. 10, boom 12 is of asubstantially rectangular or box cross section, and is constructed bywelding bottom plate 218 to side plates 219, 220 which are welded to topplate 221. Removable panels (not shown) may be provided in convenientpositions along any of the plates 218, 219, 220, 221, to provide accessfor servicing of internal componentry within first boom 12. The bottomplate 218 supports a track in the form of channels 222, 223 (also shownin FIG. 9). Channels 222 and 223 support shuttle-B1 224. Referring toFIG. 9, shuttle 224 is shown gripping a brick 225.

Shuttle

A shuttle grips a brick and is moved along the inside of the boom fromthe near end of the boom, nearly to the distal end of the boom, bytoothed belts driven by servo motors fitted to the boom. The servomotors are fitted to the boom to minimise the size and weight of themoving shuttle and also to avoid having to use cable chains or sliptracks to transfer electrical power and signals to and from theshuttles. One servo motor 256 moves the shuttle and the other servomotor 255 moves the jaws of the shuttle. A detailed description follows.

Refer to FIGS. 9, 10 and 14. Referring to FIG. 14, bottom plate 218supports a drive assembly 254 located at the distal end 270 of the firstboom 12. Drive assembly 254 has a body that supports servo motors 255and 256. Servo motor 255 drives a pulley 258 which drives an endlessbelt 251. Endless belt 251 passes around idlers 260, 261. Plate 218supports idler pulley assembly 259 (shown in FIG. 9) to turn the belt.

Servo motor 256 drives a pulley 257. Drive assembly 254 has a shaft 262that supports a large pulley 263 and a small pulley 264, forming part ofa reduction drive. An endless toothed belt 258 wraps around pulley 257and large pulley 263. A belt 266 wraps around pulley 264 and idlerpulley assembly 265 at the near end 269 of first boom. Belt 266, runningthe length of first boom 12 is driven by pulley 264.

Refer to FIGS. 9, 12 and 13. Referring to FIG. 12, shuttle-B1 224 has abody 246 which supports wheels 226, 227, 228, 229 that rotate aboutsubstantially horizontal axes, and supports wheels 230, 231, 232, 233that rotate about axes in a vertical plane. Shuttle-B1 224 supportslinear guides 234, 235. Linear guides 234, 235 respectively supportbearing cars 236, 237 which respectively support jaws 238, 239. Jaw 238is provided with rubber gripping pads 240, 241 and jaw 239 is providedwith rubber gripping pads 242, 243. Jaws 238, 239 respectively supportlead screw nuts 244, 245 at the base thereof (shown in FIG. 13). Body246 supports bearing housings 247, 248 (shown in FIG. 13) which supporta leadscrew 249. Referring to FIGS. 12 and 13, leadscrew 249 is fittedwith a pulley 250, located between the bearing housings 247 and 248.Leadscrew 249 engages with leadscrew nuts 244, 245. Body 246 supportsidler pulleys 252, 253. Tooth belt 251, shown partially in FIG. 13 andalso in FIG. 14, wraps partially around pulley 252, then pulley 250 thenpulley 253. Tooth belt 251 drives pulley 250, which in turn rotatesleadscrew 249 which moves the jaws 238, 239. Belt 265 is connected tobody 246 at a first location 267 and a second location 268. The drivetrain described allows servo motor 255 to move the jaws 238, 239together to clamp a brick 225, or apart to unclamp a brick 225. Thedrive chain described allows servo motor 256 to move the shuttle-B1along the inside of first boom 12. Thus a brick 225 can be clamped by ashuttle-B1 224 and moved from the first end 269 of first boom 12 to thesecond end 270 of first boom 12 and then brick 225 (shown in FIG. 9) canbe unclamped. As servo motor 256 moves the shuttle-B1 224 along theboom, servo motor 255 must be synchronised with servo motor 256 to avoidthe jaws 238 and 239 from inadvertent movement which could result in thebrick being released or over-tightening of the jaws, or the shuttle jawsbeing run past their intended travel limits.

It will be seen in the discussion that follows, that the tracks,shuttles and drive assemblies of sticks 15, 17, 18, and 19 follow thesame fundamental configuration as that of boom 12.

Winch

Winches and cables are used to move the telescopic sections of the boomand stick via a system of pulleys. The winch and cable system provides avery light weight means of moving the telescopic sections of thefoldable boom. It was found that electric ball screws or hydraulic ramsor toothed racks and gears could be used to move the telescopic sectionsof the boom, but these systems have a higher weight than the cable drivesystem described. The winch and cable system is detailed below.

Referring to FIGS. 10 and 41, side plate 219 supports a winch assembly713. Referring to FIG. 41, winch 713 winds cables 714, 715 thattelescopically move the second boom 14 relative to the first boom 12(shown in FIG. 1). Winch assembly 713 has bracket 716 and bracket 717supported on side plate 219. Bracket 717 supports bearing reducer 718which is driven by servo motor 719, providing a reduction drive forwinch drum 720. Bracket 716 supports a roller bearing 721 thatrotateably supports winch drum 720.

Side plate 219 supports idler pulleys blocks 722, 723, 724, 725. FIG. 42shows a view of the boom 12 with side plate 219 and bottom plate 218removed for clarity so that the second boom 14 can be seen more clearly.First boom 12 bottom plate 218 supports idler pulley blocks 728, 729,730, 731. Second boom 14 bottom plate 524 supports idler pulley blocks726, 727. Cable 714 passes in turn from the winch drum 720 to pulleyblock 722 then to pulley block 723, then pulley block 728 then throughpulley block 726 then pulley block 731 and then is fastened to thebottom plate 524 of second boom 14. Cable 714 passes in turn from thewinch drum 720 to pulley block 724, then to pulley block 725, then topulley block 729, then through pulley block 727 then through pulleyblock 730 and then is fastened to the bottom plate 524 of second boom14. The pulley blocks provide mechanical advantage so that a thin cablecan be used. Servo motor 719 rotates the input of bearing reducer 718which rotates the winch drum 720 which moves cables 714, 715 whichslides second boom 14 relative to first boom 12.

Wear blocks 799 formed from ultra high molecular weight polyethylene(UHMPE) or other suitable material, are secured to the distal end ofboom 12 and the near end of boom 14 to provide bearing surfaces for theelements to telescopingly slide. Wear blocks 799 of such material aredescribed throughout this description to provide bearing surfaces forthe telescoping parts of both the boom and the stick.

Second Boom

Referring to FIGS. 17, 18, 19, 20, 21, second boom 14 is of asubstantially rectangular or box cross section. Referring to FIG. 17,second boom 14 is constructed by welding bottom plate 524 to side plates521, 522, and welding side plates 521, 522 to top plate 523. As with thefirst boom 12, removable panels (not shown) may be provided inconvenient positions along any of the plates 521, 522, 523, 524, toprovide access for servicing of internal componentry within second boom14. Second boom 14 has a first near end 525 and a second distal end 526.Second distal end 526 supports lugs 527, 528. Referring to FIG. 18, topplate 523 supports channels 529, 530, which form a track to supportshuttle-B2 531.

Shuttle-B2 531 has jaws 532, 533 for the gripping of a brick. Top plate523 supports bracket assembly 534, which supports idler pulleys 535,536, 537. Bracket assembly 534 supports servo motors 538, 539. Servomotor 539 drives the jaws 532, 533. Servo motor 538 drives theshuttle-B2 531. Shuttle-B2 531 can move linearly from the first end 525to the second end 526 of second boom 14. The arrangement is the same asdescribed for the first boom 12 except that the servo motors 538 and 539are mounted externally on boom 14 to allow the channels 529 and 530 thatform the track within second boom 14 to extend from the near end 525, tothe distal end 526, so that the shuttle-B2 531 can traverse the entirelength of second boom 14.

Referring to FIG. 18, side plate 521 supports a boss 562. Boss 562 has abore 563. Bore 563 supports an end of dog bone link 156 seen in FIG. 1.

Refer to FIGS. 4, 20 and 21. An arrangement of energy chains 112 isprovided within the boom and stick assembly 141 to carry cables andhoses. Bottom plate 524 supports cable chains 563, 564, 565.

Rotator-B2-S1

The rotator-B2-S1 548 transfers a brick from the second boom shuttle tothe first stick shuttle. It can rotate to align with either the secondboom, or the first stick, so that the brick maintains orientation withits longitudinal extent extending with the first stick longitudinalextent, when the brick is transferred from the second boom 12 to thefirst stick 15. The rotator-B2-S1 548 has movable gripper jaws to graspthe brick. A detailed description follows.

Referring to FIGS. 20 and 22, bottom plate 524 supports Rotator-B2-S1548 from supporting bracket 540. Bracket 540 supports bearing reducer541, which supports servo motor 542. Bearing reducer 542 supports anassembly of arm 543 and base 544. Base 544 supports mount plate 547which supports servo motor 549. Base 544 also supports linear guides545, 546. Linear guide 545 supports bearing car 550 which supports jaw551. Linear guide 546 supports bearing car 552 which supports jaw 553.Mount plate 547 supports bearing 554 (see FIG. 20), which supportsleadscrew 555. Motor 549 has a toothed pulley 556, and leadscrew 555 hasa pulley 557, with endless toothed belt 558 wrapped around pulley 556and pulley 557. Jaw 551 supports nut 556′, and jaw 553 supports nut 559(shown with hidden lines in FIG. 22). Leadscrew 555 engages with nuts556′, 559. Servo motor 549 thus drives leadscrew 555 to move jaws 551and 553 together to clamp a brick, or apart to release a brick. Servomotor 542 rotates the input of bearing reducer 541. The output ofbearing reducer 541 rotates arm 543 about a horizontal axis 16, which isthe same axis as the articulated joint 23 connection of second boom 14to first stick 15. Thus arranged, rotator 548 can grasp a brick locatedin shuttle-B2 at the second end 526 of second boom 14 and transfer it toa shuttle-S1 located at the first end 561 of first stick 15.

Joint

Refer to FIG. 1. The articulated joint 23 of second boom 14 to firststick 15 about axis 16 is moved by a luffing ram 24 powered byelectricity or hydraulics and a first dog bone link 155 and a second dogbone link 156.

Refer to FIG. 23 and FIG. 24. Side plate 568 supports lug 586. Sideplate 569 supports lug 587. Side plate 568 supports boss 588. Lugs 586,587 respectively have concentric bores 589, 590. Bores 589, 590 are onaxis 16. Boss 588 has a bore 591. Bore 591 supports a pin not shown thatsupports an end of dog bone link 156.

First Stick

Refer to FIGS. 23, 24. First stick 15 has a first near end 561 and asecond distal end 566. First stick 15 is of a substantially rectangularor box cross section and welded plate construction, comprising a bottomplate 567, welded to side plates 568, 569, and side plates 568, 569welded to top plate 570. Side plate 568 supports lugs 574, 575 forconnecting an end of luffing ram 24 (shown in FIG. 1).

Stick Assembly

The stick assembly has telescopic sticks that can extend and retract.The extension and retraction is servo controlled. Each stick supportschannels that in turn support shuttles that move bricks from a firstnear end to the next stick. The shuttles move back and forth on trackswithin their respective sticks. The shuttles are provided with clamps,and can pass a brick along the stick assembly.

Stick Winch and Cables

The telescopic stick assembly is extended and retracted by a winch thatwinds cables that wrap around a system of pulleys to move the sticks.The winch is driven by a servo motor and bearing reducer. A detaileddescription follows.

Refer to FIGS. 23 and 46. Referring to FIG. 23, the top plate 570supports a winch 578. Winch 578 winds cables 579, 580 thattelescopically move the second stick 17, third stick 18, fourth stick 19and fifth stick 20 within and relative to first stick 15 (shown in FIG.46).

Winch 578 is mounted to top plate 570 by bracket 581 and bracket 582. Abearing reducer 583 is provided between servo motor 584′ and a winchdrum 584. Bracket 581 supports a roller bearing 585 (not visible) thatrotateably supports the winch drum 584, at the end thereof away from thebearing reducer 583. Top plate 570 supports pulley blocks 746, 747, 748,749, 750, 751.

FIG. 46 shows a view of the stick assembly 744. Second stick 17 supportspulley blocks 752, 753. Third stick 18 supports pulley blocks 754, 755.Fourth stick 19 supports pulley blocks 756, 757. Extension cable 580 iswrapped on winch drum 578 and then passes through pulleys 750, 751, thento second stick 17 pulley block 752, then to pulley block 753, then tothird stick 18 pulley block 754, then to pulley block 755, then tofourth stick 19 pulley block 756, then to pulley block 757, then to atermination 758 on fifth stick 20. Tension on cable 580 forces the stickassembly 744 to extend.

Referring to FIG. 47, retraction cable 579 is wrapped on winch drum 578and then passes through pulley blocks 746, 747, 748 and 749 and thenruns internally inside stick assembly 744 to termination 759 on fifthstick 20. Tension of cable 579 forces the stick assembly 744 to retract.

FIG. 48 shows a view of stick assembly 744. Cables 759, 760 and 761 actto keep the extension of each stick, relative to its neighbours,similar. Second stick 17 supports pulley block 762. First stick 15supports a termination 765 of first end 771 of cable 759. Cable 759passes through pulley block 762 and third stick 18 supports atermination 766 of second end 772 of cable 759. Third stick 18 supportsa pulley block 763. Second stick 17 supports a termination 767 of firstend 773 of cable 760. Cable 760 passes through pulley block 763. Fourthstick 19 supports a termination 768 of second end 774 of cable 760.Fourth stick 19 supports pulley block 764. Third stick 18 supports atermination 769 of first end 775 of cable 761. Cable 761 passes throughpulley block 764. Fifth stick 20 supports a termination 770 of secondend 776 of cable 761.

First Stick

Referring to FIGS. 23 and 24, the top plate 570 supports a track in theform of longitudinally extending channels 571, 572, inside the stick 15.Channels 571, 572 run from the first near end 561 of first stick 15,nearly to the second distal end 566, save room for the drive assembly592 at the end of the track, inside the first stick 15. Channels 571,572 slideably support shuttle-S1 573. Shuttle-S1 573 has jaws 576, 577provided to clamp a brick.

Top plate 570 supports drive assembly 592 inside first stick 15, in thesame manner as that of the first boom 12. Top plate 570 supports bracket593, which supports idler pulleys 594, 595, 596, 597. Servo motors notshown on drive assembly 592 move the shuttle-S1 573 along the top of andinside first stick 15 and can open and close jaws 576, 577 to grip orrelease a brick. Thus shuttle 573 can grasp a brick at first near end561 of first stick 15 and move it to or toward second distal end 566 offirst stick 15, then unclamp the brick not shown. The mechanism for thisfunctions in the same manner as that of the first boom 12 and itsshuttle. The jaws 576 and 577 each include a deviation 576′ and 577′which aligns with the bracket assembly 534 of second boom 14, to provideclearance to receive bracket assembly 534 at the distal end of secondboom 14, when the shuttle-S1 573 moves in to take a brick fromrotator-S2-S1 548 when second boom 14 and first stick 15 are aligned inline, as shown in FIG. 57C.

Second Stick

Refer to FIGS. 25, 26, 27. Referring to FIG. 25, second stick 17 has afirst near end 598 and a second distal end 599. Second stick 17 ishollow and internally supports a shuttle that moves bricks from thefirst near end 598 to or toward the second distal end 599.

Second stick 17 is preferably constructed from carbon fibre sandwichpanels for low weight. Alternatively, second stick 17 way be welded withmetal plates. Second stick 17 is of a substantially rectangular or boxcross section. Second stick 17 is constructed by welding or bondingbottom plate 600 to side plates 601, 602. Side plates 601, 602 arewelded or bonded to top plate 603. Bottom plate 600 supports a trackformed by longitudinally extending channels 604, 605. Channels 604, 605support shuttle-S2 606 for movement therealong. Shuttle-S2 606 has jaws607 and 608 to grasp a brick. Referring to FIG. 26, bottom plate 600supports bracket 609 which supports idler pulleys 610, 611, 612, 613.Referring to FIG. 27, bottom plate 600 supports drive assembly 614located at the distal end 599 of second stick 17, which moves belts 615and 616, in order to move shuttle-S2 606 (shown in FIG. 26) and open andclose jaws 607, 608, in the same manner as that of the first boom 12 andits shuttle. Thus shuttle-S2 can grasp a brick located at the first nearend 598 of second stick 17 and move the brick to or toward the seconddistal end 599 of second stick 17 and unclamp the brick. The secondstick 17 has a void in the top plate 603 at the near end 598 (shown inFIG. 26), which is opposite the track formed by channels 604 and 605.This allows the shuttle-S1 573 of the first stick 15 to line up abovethe shuttle-S2 606 to enable the clamps thereof to transfer a brick fromshuttle-S1 573 to shuttle-S2 606.

Third Stick

Refer to FIGS. 28, 29 and 30. Referring to FIG. 28, third stick 18 has afirst near end 618 and a second distal end 619. Third stick 18 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, third stick 18 may be constructed with welded metalplates. Third stick 18 is of a substantially rectangular or box crosssection. Third stick 18 is constructed by welding or bonding bottomplate 620 to side plates 621, 622. Side plates 621, 622 are welded orbonded to top plate 623. Referring to FIG. 29, top plate 623 supports atrack formed by longitudinally extending channels 624 and 625 whichextend from the first near end 618 to the drive assembly 634 located atthe second distal end 619, shown on FIG. 30. Channels 624, 625 supportshuttle-S3 626 for movement along third stick 18 from first near end 618to or toward second distal end 619. Shuttle-S3 626 has jaws 627 and 628,to clamp a brick. Top plate 623 supports bracket 629. Bracket 629supports idler pulleys 630, 631, 632, 633. Referring to FIG. 30, topplate 623 supports drive assembly 634 at the second distal end 619,which moves belts 635 and 636. Drive assembly 634 can move shuttle-S3626 and open and close jaws 627, 628. Thus shuttle-S3 can grasp a bricklocated at the first end 618 of third stick 18 and move said brick to ortoward the second end 619 of second stick 18 and unclamp the brick, inthe same manner as that of the first boom 12 and its shuttle. The thirdstick 18 has a void in the bottom plate 620 at the near end 618, whichis opposite the track formed by channels 624 and 625. This allows theshuttle-S2 606 of the second stick 17 to line up above the shuttle-S3626 to enable the clamps thereof to transfer a brick from shuttle-S2 606to shuttle-S3 626.

Fourth Stick

Refer to FIGS. 31, 32, 33. Referring to FIG. 31, fourth stick 19 has afirst near end 637 and a second distal end 638. Fourth stick 19 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, fourth stick 19 may be constructed from welded metalplates. Fourth stick 19 is of a substantially rectangular or box crosssection. Fourth stick 19 is constructed by welding or bonding bottomplate 640 to side plates 641, 642. Side plates 641, 642 are welded orbonded to top plate 643. Bottom plate 640 supports a track formed bylongitudinally extending channels 644, 645. Channels 644, 645 extendfrom the near end 637 to drive assembly 654 located at the distal end,and support shuttle-S4 646 (shown on FIG. 32) for linear movementtherealong. Referring to FIG. 32, shuttle-S4 646 has jaws 647 and 648 tograsp a brick. Bottom plate 640 supports bracket 649 at the near end 637which 649 supports idler pulleys 650, 651, 652, 653. Referring to FIG.33, bottom plate 640 supports drive assembly 654 at the distal end 638,inside fourth the stick 19. Drive assembly 654 moves belts 655 and 656in order to move shuttle-S4 646 along fourth stick and open and closejaws 647, 648, in the same manner as that of the first boom 12 and itsshuttle. Thus shuttle-S4 646 can grasp a brick located at the first end637 of fourth stick 19 and move it to or toward the second end 638 offourth stick 19 and unclamp the brick. Referring to FIG. 32, the fourthstick 19 has a void in the top plate 643 at the near end 637, which isopposite the track formed by channels 644 and 645. This allows theshuttle-S3 626 of the third stick 18 to line up above the shuttle-S4 646to enable the clamps thereof to transfer a brick from shuttle-S3 626 toshuttle-S4 646.

Fifth Stick

Refer to FIGS. 34, 35, 36 and 37. Referring to FIG. 34, fifth stick 20has a first near end 657 and a second distal end 658. Fifth stick 20 ispreferably constructed from carbon fibre sandwich panels for low weight.Alternatively, fifth stick 20 may be constructed from welded metalplates. Fifth stick 20 is of a substantially rectangular or box crosssection. Fifth stick 20 is constructed by welding or bonding bottomplate 660 to side plates 661, 662. Side plates 661, 662 are welded orbonded to top plate 663. Top plate 663 supports a track formed bylongitudinally extending channels 664, 665, which extend from the nearend 657 to the drive assembly 663, along the inside of the fifth stick20. Referring to FIG. 35, channels 664, 665 support shuttle-S5 666 forlinear movement therealong. Shuttle-S5 666 has jaws 667, 668 provided togrip a brick. Top plate 663 supports bracket 669 at the near end 657which supports idler pulleys 670, 671, 672, 673. Referring to FIG. 36,top plate 663 supports drive assembly 674 at the distal end 658. Driveassembly 674 moves belts 675 and 676 in order to move shuttle-S5 666 andopen and close jaws 667, 668 (shown in FIG. 35). Drive assembly 674moves belts 675 and 676 in order to move shuttle-S5 666 along fifthstick and open and close jaws 647, 648, in the same manner as that ofthe first boom 12 and its shuttle. Shuttle-S5 666 can grasp a brickpresented by shuttle-S4 646 located through a void located at the nearend 657 of the bottom plate 660. Shuttle-S5 666 then moves the brickalong the inside of fifth stick 20 to the second distal end 658 of fifthstick 20, where it will be unclamped.

The panels or plates making up each of the first stick 15, second stick17, third stick 18, fourth stick 19 and fifth stick 20 may be providedwith removable panel portions (not shown) to provide access forservicing of internal componentry within each stick.

Boom Cable Chains

Cable chains are used to route power and signals to and from the servomotors. The arrangement of the cable chains provides a compact over allcross section of the folding boom.

Referring to FIG. 43, bottom plate 218 of first boom 12, supports afirst end 735 of cable chain 112. Cable chain 112 is also visible inFIGS. 11, 18, 19. The top plate 22 of second boom 14, supports a secondend 736 of cable chain 112.

First near end 637 of fourth stick 19 supports a first end 737 of cableduct 733. Second end 738 of cable duct 733 supports a first end 739 ofcable chain 734. The bottom plate 660 of fifth stick 20, supports thesecond end 740 of cable chain 734. Cable chain 734 and cable duct 733are also visible in FIG. 34.

Referring to FIG. 44, the bottom plate 524 of second boom 14, supports afirst end 741 of cable chain 563. The top plate 623 of third stick 18supports a second end 742 of cable chain 563. Cable chain 563 is alsovisible in FIGS. 17, 18, 19, 20.

Referring to FIG. 45, the bottom plate 524 of second boom 14 supports afirst end 743 of cable chain 564. The top plate 643 of fourth stick 19supports a second end 744′ of cable chain 564. Cable chain 564 is alsovisible in FIGS. 17, 18, 19, 20.

Referring to FIG. 1, cables (not shown) are routed from an electricalcabinet through the frame 3, through the centre of slew ring 11, upthrough the inside of tower 10 and into first boom 12, then into cablechain 112 (shown in FIG. 43), then into second boom 14. Referring toFIG. 43, cables (not shown) are routed from second boom 14, to firststick 15, and to cable chain 565 and then into second stick 17, and asshown in FIG. 44 also into cable chain 563 and then into third stick 18,and as shown in FIG. 45 also into cable chain 564 and then into fourthstick 19.

Referring to FIG. 43, (cables not shown) are routed from fourth stick19, through cable duct 733 into cable chain 734 then into fifth stick20. From fifth stick 20, cables not shown are routed to the brick layingand adhesive applying head 32.

Flipper

Refer to FIGS. 37, 38, 39. Referring to FIG. 37, a pivotable clamp inthe form of a flipper assembly 687 has jaws 690 and 693 to grip a brickand can then translate and rotate the brick to move it past an adhesiveapplication nozzle 121, 122, 123, 124 and 125 and then present the brickfor transfer to the laying arm. The flipper assembly 687 is located atthe distal end 658 of the fifth stick 20.

FIGS. 58A to 58H, 58J to 58N, 58P, and 58Q show a sequence for a brickas it passes from the fifth stick to its laid position.

During the laying of bricks, the brick laying and adhesive applying head32 is held at a constant tilt relative to the ground. The pose of thefoldable boom is varied to position the brick laying and adhesiveapplying head 32 appropriately for the brick laying and adhesiveapplying head 32 to lay bricks in the required position. The angle ofthe stick assembly, varies according to the required pose of thefoldable boom. The flipper assembly 687 is used to receive a brick fromthe stick assembly (FIG. 58A) and move the brick to a position suitablefor an adhesive applicator 777 in the brick laying and adhesive applyinghead 32 to apply glue to said brick (FIGS. 58D-58G), and then for thebrick laying gripper 44 to lay the brick (FIG. 58Q). Referring to FIG.38, the flipper assembly 687 rotates about axis 33. The flipper assembly687 has a gripper with jaws 690 and 693 that can slide toward or awayfrom the axis of rotation 33 (which is the same horizontal axis of themount of the brick laying and adhesive applying head 32 to the end offifth stick 20). The gripper can extend into the fifth stick 20 to graspa brick (FIG. 58B). The gripper then retracts to a position near theaxis of rotation 33 (FIG. 58C) so that the brick is clear of the fifthstick 20. The brick is then rotated for the application of adhesive(FIG. 58D). The adhesive application nozzles are extended out over thebrick (FIGS. 58E, 58F). The adhesive nozzles direct adhesive downwardsso that gravity assists in applying the adhesive to the brick. Theadhesive application nozzles are retracted whilst directing adhesiveonto the brick (FIG. 58G). The flipper 687 then rotates (FIG. 58H) toorient the brick vertically (FIG. 583), so that adhesive applicationnozzles can apply adhesive to the end of the brick. The flipper thenrotates (FIG. 58K) to invert the brick (FIG. 58L) so that the adhesiveis on the bottom of the brick. The flipper 687 then extends the gripperout (FIG. 58M), to present the brick in a position where the bricklaying gripper 44 can then grasp the brick (FIG. 58N). The flippergripper then releases the brick and the flipper gripper then translatesin a reverse direction whilst the flipper rotates in a reverse rotation(FIG. 58P, 58Q) so that the gripper is returned to its starting position(FIG. 58A).

A detailed description of the flipper assembly follows.

Refer to FIG. 37. Fifth stick 20 supports the flipper assembly 687 aboutthe same horizontal axis 33 as the brick laying and adhesive applyinghead 32 is attached to the distal end of the fifth stick 20 (see FIG.58A).

Refer to FIGS. 36, 37, 38 and 39. Referring to FIG. 37 the fifth stick20 supports a bearing reducer 677 and a servo motor 678. Bearing reducer677 supports an arm 679 of the flipper assembly 687 on its output, and aservo motor 678 rotates the input of bearing reducer 677. This rotatesarm 679 and hence the flipper assembly 687 about axis 33. Referring toFIG. 38, the arm 679 supports a linear guide 680 which slideablysupports a bearing car 681 for movement between a first end 707 and asecond end 708 of the arm 679. A base plate 682 mounts to the bearingcar 681, perpendicularly to the travel extent thereof. Referring to FIG.39, a servo motor 684 for movement of the base plate 682 is mounted viaa spacer 683 to the arm 679. Referring to FIG. 38, a servo motor 686 formovement of jaws 690 and 693 is mounted on motor mount plate 685 whichis supported on base plate 682. Base plate 682 supports linear guides688, 689 which slideably support bearing cars 691 and 692 respectively.Bearing car 691 supports jaw 690, and bearing car 692 supports jaw 693.Servo motor 686 drives pulley 694 which drives pulley 696 connected toleadscrew 695 via endless toothed belt 697. Referring to FIG. 39, baseplate 682 supports a bearing 700 which rotateably supports the leadscrew695. Referring to FIG. 38, jaw 690 supports a nut 698, and jaw 693supports a nut 699, which nuts 698 and 699 are engaged with theleadscrew 695. Thus servo motor 685 drives the jaws 690 and 693 to clampand unclamp a brick.

Referring to FIG. 38, the arm 679 supports a bracket 701 with an idlerpulley 702 near end 708. Servo motor 684 (shown in FIG. 39) drives apulley 703, which drives pulley 702 via endless belt 704. The base plate682 has a clamp plate 705 (shown in FIG. 39) which clamps belt 704. Thusthe servo motor 684 linearly moves base plate 682 along linear guide680.

Refer to FIG. 37. Servo motor 678 can rotate arm 679 so that linearguide 680 is aligned parallel with the channels 664, 665 in fifth stick20.

Jaws 690 and 693 can be moved by servo motor 684 towards the seconddistal end 658 of fifth stick 20 to pick up a brick (see FIG. 58B) thatis being held by jaws 667, 668 of shuttle-S5 666. Servo motor 686 canthen close jaws 690 and 693 to grasp the brick. Servo motor 684 can thenmove jaws 690, 693, holding the brick towards first end 707 of arm 679(see FIG. 58C). Servo motor 678 can then rotate arm 679 so that the topsurface of said brick is presented flat, ready for adhesive applicationby the adhesive application system 150 (see FIGS. 58D to G).

Optionally, servo motor 684 can then rotate arm 679 through 90 degreesso that the end of said brick is presented flat, ready for adhesiveapplication by the adhesive application system 150 (see FIGS. 58H and3). It should be noted that in some structures, such as for walls thatwill be rendered, it is not necessary to apply adhesive to the vertical(or “perp”) joints of the bricks. Optionally, servo motor 684 can thenrotate arm 679 through 180 degrees so that the opposite end of saidbrick is presented flat, ready for adhesive application by the adhesiveapplication system 150, thereby applying adhesive to the bottom and bothends of said brick.

Servo motor 684 can then rotate arm 679 through 180 degrees (or 90 or270 degrees, depending on which faces of the brick had adhesive appliedto them), so that said brick is inverted, ready to be picked up by thelaying arm gripper 44 (see FIGS. 58K to Q). In this way the glue isapplied to the bottom of said brick that will be laid by the laying arm40.

FIG. 53 shows a side view of the brick laying and adhesive applying head32 and fifth stick 20. FIG. 53 shows the sequence of the brick 797 froma first position 791, to a second position 792, to a third position 793to a fourth position 794 to a fifth position 795 to a sixth position796. In first position 791, brick 797 is gripped by shuttle-S5 666 (notshown in FIG. 53). The flipper jaws 690 and 693 are moved to grasp thebrick 797 and then shuttle-S5 666 releases the brick 797. The brick 797is then translated to second position 792, then rotated to thirdposition 793. Adhesive is then applied to the brick 797. Brick 797 isthen optionally rotated to vertical position 794. Brick 797 is thenrotated to a fifth position 795 and then translated to a sixth position796.

Adhesive

Referring to FIG. 1, the frame 3 supports an adhesive container and anadhesive pump. The adhesive pump supplies pressurised adhesive to fluidconveying apparatus in the form of a hose which runs out along the boomand through the flexible energy chains 112 (shown in FIG. 43), 564(shown in FIG. 45) and 740 (shown in FIG. 43) provided in the telescopicboom and telescopic sticks, to the brick laying and adhesive applyinghead 32. Adhesives can be one pack or two pack, and should have someflexibility when set in order to avoid fracturing due to unevenexpansion and contraction in the built structure. Suitable adhesives aresingle pack moisture curing polyurethane such as Sika “Techgrip”,Hunstman “Suprasec 7373” or Fortis AD5105S, single pack foamingpolyurethane such as Soudal “Souda Bond Foam” or Weinerberger “Dryfix”,two part polyurethane such as that made by Huntsman, MS Polymer(Modified Silane Polymer) such as HB Fuller “Toolbox”, two part epoxysuch as Latipoxy310 and methacrylate adhesive such as “Plexus”. It wouldbe possible but less desirable (due to strength, flexibility and “potlife” and clean up reasons) to utilise water based adhesives such aslatex, acrylic or cement based adhesives similar to various commerciallyavailable tile glue or Austral Bricks “Thin Bed Mortar”.

Refer to FIGS. 5 and 6. The adhesive applicator 777 has an adhesive headfitted with nozzles 121, 122, 123, 124 and 125, shown schematically inFIG. 6. The adhesive flow is controlled by electrically operable valves118 and 119, located in a manifold head 117, close to the nozzles 121,122, 123, 124 and 125, which are also supported on the manifold head117. Space within the laying head is very restricted. The nozzlesprovided in two groups comprising a central group of nozzles 121, 122and 123 supplied by valve 118, and a peripheral group of two outernozzles 124 and 125 supplied by valve 119. The manifold head 117 issupported on a mechanism that can project the nozzles out to reach thelength of a brick, and retract the nozzles to provide clearance so thatthe brick can be rotated and also by retracting the nozzles clearance isprovided so that the laying head can be folded against a retracted stickassembly for compact transport. To achieve the extension and retraction,the nozzles are supported on a chain that can only bend one way and thechain is extended or retracted by a sprocket driven by a servo motor. Adetailed description follows.

Refer to FIGS. 5, 6, 40 and 49. Referring to FIG. 40, the brick layingand adhesive applying head 32 supports an adhesive applicator assembly777. Referring to FIG. 49, the adhesive applicator assembly 777 has acurved guide 113 attached to the brick laying and adhesive applying head32. The curved guide 113 supports a tongue member in the form of asliding chain 114 that can only bend one way. The sliding chain 114 ismoved by a servo powered sprocket 115. The brick laying and adhesiveapplying head 32 supports a straight guide 784 into which the slidingchain 114 may be retracted. The distal end 116 of the sliding chain 114supports a manifold 117 that supports two valves 118, 119. Each valve118, 119 is connected to the pressurised adhesive supply 120 provided bythe adhesive pump 111 mounted to the frame 3 (shown in FIG. 5). Thefirst valve 118 is connected to three central glue nozzles 121, 122,123, and the second valve 119 is connected to two outer glue nozzles124, 125 (shown schematically in FIG. 13). The inner nozzles 121, 122,123 are provided to allow glue to be applied to the top face of a narrowor internal brick, while the outer nozzles 124, 125 allow glue to beapplied to the outer edges of the top face of a wide or external brick126. The valves 118, 119 may be operated individually or together tosupply glue to the inner nozzles 121, 122, 123, the outer nozzles 124,125 or all nozzles 121, 122, 123, 124 and 125.

Refer to FIGS. 50 and 51. Referring to FIG. 50, the sliding chain 114has a plurality of body portions in the form of hollow links 778 and aplurality of chain links in the form of joiner links 779. Joiner links779 are standard items used to join power transmission chain, such as BSroller chain 16-B1 or ANSI roller chain 80-1. Referring to FIG. 51,hollow link 778 is provided with lugs 780, 781 to engage the pins 782 ofjoiner links 779 shown in FIG. 50. Hollow link 778 is provided with alongitudinally extending hole 783 for the passage of cables (not shown)and the pressurised adhesive 120 (see FIG. 13). The hollow links haveends that contact each other to prevent over extension of the slidingchain, allowing the sliding chain to be extended outward from the tip ofthe curved guide and retain a straight configuration, being bendableupward only, about the axes provided by the connection of the hollowlinks with the joiner links.

Referring to FIG. 52, the straight guide 784 is fitted with a lid 788.In FIG. 49 curved guide 113 is shown with the lid 787 removed forclarity. Straight guide 784 is shown without the lid 788 for clarity.

Referring to FIG. 50, consider the example of first hollow link 778,joiner link 779 and second hollow link 784′. It can be seen that secondhollow link 784′ can pivot upwards relative to first hollow link 778,but second hollow link 784′ cannot pivot downwards relative to firsthollow link 778. By extension of the logic to the plurality of hollowlinks 778 and joiner links 779, the sliding chain 114 can only curveupwards and not curve downwards.

Preferably the hollow links 778 are manufactured from a material with alow coefficient of friction such as acetal copolymer or UHMWPE (UltraHigh Molecular Weight Polyethylene) plastic. The curved guide 113 andstraight guide 784 may be manufactured from a material with a lowcoefficient of friction such as acetal plastic.

FIG. 52 shows a top view of straight guide 784. The straight guide 784is provided with grooves 785, 786 so that joiner links 779 do not touchstraight guide 784. Straight guide 784 may then be constructed from amaterial such as aluminium alloy which is more robust than acetalplastic.

Referring to FIG. 49, the curved guide 113 is also provided with grooves789, 790 so that joiner links 779 do not touch curved guide 113. Curvedguide 113 may then also be constructed from a material such as aluminiumalloy which is more robust than acetal plastic.

Brick Laying and Adhesive Applying Head

Refer to FIG. 40. The brick laying and adhesive applying head 32supports a brick laying head in the form of a spherical geometry robot36 and the adhesive applicator assembly 777 along with a vision systemand tracking system. After application of adhesive as described above,the brick laying and adhesive applying head 32 takes a brick from thejaws 690 and 693 of the flipper assembly 687 and moves it to a positionwhere it is laid. The laying head also compensates for movement anddeflection of the boom, so that the brick is laid in the correctposition.

Refer to FIGS. 1, 5 and 40. Referring to FIG. 40, the articulated bricklaying and adhesive applying head 32 has a body 801 with arms 803 and805 forming a clevis which extends obliquely downward from the body 801.The arms 803 and 805 have apertures 807 and 809 to receive pins topivotally mount the head 32 and the flipper assembly 687 about secondhorizontal axis 33 at the distal end 658 of the fifth telescopic stick20 (see FIG. 1). Referring to FIG. 1, the brick laying and adhesiveapplying head 32 articulates about horizontal axis 33 substantiallyparallel to the articulation axis 16 of the first stick 15 and thearticulation axis 13 of the first boom 12. The pose of the brick layingand adhesive applying head 32 is controlled by movement of a ram 35.

Referring to FIG. 40, the articulated brick laying and adhesive applyinghead 32 supports a brick laying head comprising a spherical geometryrobot 36. The spherical geometry robot 36 has a linearly extendable arm40 with a brick laying clamp in the form of a gripper 44 fitted at thelower end thereof. Referring to FIG. 1, the spherical geometry robot 36has the following arrangement of joints: arm mount-roll angle 37, armmount-pitch angle 38, arm sliding (arm length or linear extension) 39,wrist pitch angle 41, wrist roll angle 42, gripper yaw angle 43 and withgripper 44 fitted to rotate about yaw axis 45. This configurationprovides pole free motion within the working envelope.

Referring to FIGS. 40 and 61, to achieve the arm mount-roll angle 37adjustment, the body 801 supports a servo motor 810 with a belt drivinga bearing reducer 812 connected to the base 811 of a clevis 813, thebase being rotatable relative to the body 801 about a horizontal axiswhich runs normal to the clevis 813 axis. To achieve the arm mount-pitchangle 38 adjustment, the clevis 813 supports about its axis 814 a servomotor 816 attached to the body 801 driving via a belt a bearing reducer818 connected to a base 815 for the arm 40.

The arm 40 has linear guides 820 which co-operate with bearing cars 822(see FIG. 62) on the base 815 to guide linear extension of the armrelative to the mount, to allow the arm 40 to move in a direction(typically straight up and down, but this depends on the pose) normal tothe axis 814 of the clevis 813 to provide sliding movement of the arm40. This linear extension of the arm is controlled by a servo motor 823attached to the base 815 with reduction drive pulleys connected by atoothed belt 825 driving a pinion 827 engaging a rack 829 locatedextending along the arm 40.

The brick laying clamp/gripper 44 mounts for controlled rotation by aservo motor 830 driving a bearing reducer 831 about an axis normal andperpendicular to the plane of its jaws 833, 835 and bearing reducer on aclevis 817 to provide the gripper yaw angle 43 adjustment; a universaljoint formed by mechanism 819 comprising servo motor 837 and bearingreducer 839 connected by toothed belt 841 and pulleys provides wristpitch angle 41 adjustment; and mechanism 821 comprising servo motor 843and bearing reducer 845 driven by toothed belt 847 and pulleys provideswrist roll angle 42 adjustment (shown in FIG. 1). Details of these servomotors and drives can be seen in FIG. 85.

The brick laying and adhesive applying head 32 supports a hook 151 thatcan be used to lift items such as windows, doors, lintels and otheritems not shown.

Refer to FIG. 5 and FIG. 6. The brick laying and adhesive applying head32 supports machine vision cameras 127, 128 mounted to view both sidesof the brick 126 shown schematically in FIG. 13.

The jaws 835, 833 of the laying head gripper 44 are independentlymovable by independent lead screws 849, 851, engaged with nuts 853, 855connected with the jaws 835, 833, and moveable by servo motors 857, 859,via drive belts 861, 863 respectively. This allows the offset grippingof a brick. The arrangements for moving the jaws 835, 833 use leadscrews 849, 851 and co-operating nuts 853, 855, driven by separate servomotors 857, 859, respectively, similar to that as described for othergrippers utilised elsewhere in the embodiment, apart from the drives forthe jaws being separate in order to allow independent movement of thejaws.

As can be seen in FIG. 40, when considered with FIG. 49, the straightguide 784 of the adhesive applicator assembly 777, into which thesliding chain 114 may be retracted, is mounted in the body 801 of thebrick laying and adhesive applying head 32, behind the servo motor withbearing reducer that connects to clevis 813. The curved guide 113 of theadhesive applicator assembly 777 descends/depends downwardly obliquely,substantially following the extent of the arms 803 and 805 for a shortdistance, before curving toward horizontal so that the sliding chain ispresented extending substantially level, subject to the alignment of thebrick laying and adhesive applying head 32 as controlled by the ram 35,and presented above where the flipper assembly 687 holds the brick. Withthis arrangement, the adhesive applicator assembly 777 is kept clear ofpositions through which arm 40 and gripper 44 of the spherical geometryrobot 36 could be required to move.

Tracker and Slab Scan

Referring to FIGS. 1, 5, 40, the top of the brick laying and adhesiveapplying head 32 supports a tracker component 130. The tracker component130 may be a Leica T-Mac or an API STS (Smart Track Sensor). Alternatelytracker component 130 may be a single SMR (Spherical Mount Reflector) orcorner cube reflector, or two or three SMRs or corner cube reflectors ora Nikon iGPS or any other suitable tracking device. Preferably thetracker component 130 provides real time 6 degrees of freedom positionand orientation data at a rate of preferably greater than 10 kHz, orpreferably 1000 Hz to 10 kHz, or preferably at a rate of 500 Hz to 1000Hz or preferably a rate of 300 Hz to 500 Hz or 100 Hz to 300 Hz or 50 Hzto 100 Hz or 10 Hz to 50 Hz. The laying arm 40 and or the gripper 44 ofthe laying arm 40 may support a second or third tracker component 131,132 of the same or different type to the first tracker component 130.

Referring to FIG. 3, a tracker component 133 or components, 133, 134,135 are set up on the ground adjacent to the concrete slab 136 or on anearby structure. The tracker component 130 on the laying headreferences its position relative to the tracker component 133 orcomponents 133, 134, 135 set up on the ground or structure.

Referring to FIG. 5, the brick laying and adhesive applying head 32supports a camera 137 that views the ground, slab 136 or structure orobjects below it. The brick laying and adhesive applying head 32 isprovided with laser or light projectors 138 that project dots or lines139 onto the ground, footings, slab 136 or objects below it. Machinevision is used to determine the 3D shape of the ground, footings, slab136 or objects below the laying head. Alternatively, the brick layingand adhesive applying head 32 is fitted with a laser scanner 140. Afterpositioning the truck and unfolding the boom, the brick laying andadhesive applying head 32 is moved around by moving the boom and stickassembly 141 so that the brick laying and adhesive applying head 32 isoptionally moved around the edge of the slab 136 and optionally aboveall positions that will be built upon. The machine vision system 143 orscanner 140 scans the slab 136 and the areas to be built on to firstlyalign the slab 136, machine 2 and working coordinate systems to theircorrect locations and secondly to quality check the slab 136 and checkits flatness and level. If the slab 136 is not flat or level withintolerance the first course of bricks or selected bricks not shown can beindividually machined, prior to being transported to the tower 10 andboom and stick assembly 141, to correct the out-of-level, flatness orheight. Optionally a brick may have a groove or notch or pocket machinedin it to avoid a bump or defect or object (such as a pipe projectingthrough the slab) on the slab 136.

As the brick laying and adhesive applying head 32 lays a brick 144, themachine vision 143 or laser scanner 140 is used to measure the laidbrick 144 so that the height of the laid brick 144 is stored and laterused to adjust the laying height of the dependant bricks that are laidon top of it on the next course. If the height is over tolerance, thedependant bricks above it can be machined to a reduced thickness by therouter 47.

The concrete slab 136 may alternatively be a slab of earth, rock, wood,plastic or other material or a steel deck or footings. The slab 136 maybe on the ground or suspended.

Harsh Environment

In an adaptation of the telescoping boom, foldable boom or articulatedtelescoping boom, with radiation protection, the booms could be used forerecting containment structures in nuclear disaster zones.

In a further adaptation of the booms, they may be adapted to work in alow pressure atmosphere or in a vacuum and in the presence of ionisingradiation. In this format with an integral automated brick or blockmaking unit, the booms could be used for building structures on the moonor Mars or in other extra-terrestrial locations.

Advantages of the Invention

In the embodiment with the boom incorporated in a vehicle, the inventionprovides an improved automated brick laying machine that is compact andmobile and able to drive on public roads. The arrangement andconfiguration of the boom allows the machine to have a very largeworking envelope whilst also being compact for road travel. Analternative embodiment is envisaged where the boom, with or withouttower and slewing ring, could be assembled atop a tower, and inparticular a jack-up tower, with one or more telescoping booms locatedinside the jack-up tower, and an articulated telescoping boom locatedatop the jack-up tower. Such an arrangement could be used to construct amulti-storey building, which would be beyond the reach of the vehiclemounted articulated telescoping boom.

To build common house size structures, the articulated telescoping boomneeds to reach out 30 m. To manoeuvre on suburban roads a short truck isadvantageous. To fit on small building sites a compact machine isadvantageous. Bricks being conveyed along the boom according to theembodiment, are restrained, so that they can't fall and damagestructures or injure personnel. By conveying the bricks along the insideof the boom, the cross section of the boom can be made smaller than thetotal cross section of a boom with external guarding to containexternally conveyed bricks. The smaller boom cross section enables asmaller and more compact machine to be built. The present invention hascable chains routed inside the boom. By conveying the bricks internally,and routing the services internally, the structural cross section of theboom is maximised for a given over all cross section, thereby increasingthe stiffness of the boom which reduces the dynamic displacement of theboom. A light weight boom is also possible due to the large crosssection.

The present invention utilises a series of shuttles that transfer abrick from one shuttle to the next. This system has the advantage thatthe movement of bricks along the boom is completely independent of thebrick preparation or laying processes. In this way, the laying rate canbe kept as high as possible. Both the brick preparation, the bricktransport and the laying process can proceed at the individual maximumrates, limited only by the availability of the bricks into each process,and the availability of a consumer process for the output of the bricks.

The invention is intended to build all of the external and internalwalls of a structure. Whilst it would be possible for the invention tobuild only some of the brick walls in a structure, with the remainingwalls being manually constructed later with manually laid bricks ormanually placed stud walls or precast panels, it should be understoodthat the invention allows the rapid and accurate placement of bricks andconstruction of brick walls faster and at a cost equal to or lower thanthe cost of manually built walls using bricks or stud framing or precast concrete.

It should be appreciated that the scope of the invention is not limitedto the particular embodiment described herein, and the skilled addresseewill understand that changes can be made without departing from thespirit and scope of the invention.

The reference in this specification to any prior publication (orinformation derived from it), or to any matter which is known, is not,and should not be taken as an acknowledgment or admission or any form ofsuggestion that that prior publication (or information derived from it)or known matter forms part of the common general knowledge in the fieldof endeavour to which this specification relates.

Throughout this specification and the claims which follow, unless thecontext requires otherwise, the word “comprise”, and variations such as“comprises” and “comprising”, will be understood to imply the inclusionof a stated integer or step or group of integers or steps but not theexclusion of any other integer or step or group of integers or steps.

The invention claimed is:
 1. A foldable boom for conveying an item, said foldable boom being foldable about at least one folding axis, said foldable boom being locatable in a folded stowed position, and moveable to unfolded extended positions; said foldable boom having a near end arranged for pivotal movement about a first horizontal axis located on a turret, said turret being rotatable about a vertical axis; said foldable boom having first conveying apparatus to convey an item therealong, internally within said foldable boom, to a remote end of the foldable boom; wherein said foldable boom is foldable about a first folding axis, and a pivoting shuttle equipped with a clamp to releasably hold an item is provided at said first folding axis to transfer said item between said first conveying apparatus in boom elements connected about said first folding axis.
 2. A foldable boom as claimed in claim 1 wherein at least one of: a. said turret has a carousel extending at least partially around said turret near the base thereof, said turret having second conveying apparatus to convey an item vertically from said carousel to said first conveying apparatus, said carousel being rotatable about a vertical axis to present an item for access by said second conveying apparatus; and, b. said first conveying apparatus comprises at least one shuttle equipped with a clamp to releasably hold an item, said shuttle running along a track extending along said foldable boom.
 3. A foldable boom as claimed in claim 2 wherein said foldable boom comprises a first boom element and a second boom element pivotable about said first folding axis spaced from said first horizontal axis, and parallel therewith and wherein at least one of: a. each of said first boom element and said second boom element has a track and at least one said shuttle; and, b. at least one of said first boom element and said second boom element, has further elements arranged in telescoping interconnection.
 4. A foldable boom as claimed in claim 1 wherein said foldable boom comprises a first boom element and a second boom element pivotable about said first folding axis spaced from said first horizontal axis, and parallel therewith and wherein at least one of: a. each of said first boom element and said second boom element has a track and at least one said shuttle; and, b. at least one of said first boom element and said second boom element, has further elements arranged in telescoping interconnection.
 5. A boom for conveying an item, said boom having a near end arranged for pivotal movement about a first horizontal axis located from a top of a turret, said turret being rotatable about a vertical axis and said boom rotating therewith; said boom having first conveying apparatus to convey an item therealong, to a remote end of the boom; said turret having a carousel on which said item may be placed, said carousel extending at least partially around said turret near the base thereof, said turret having second conveying apparatus to convey said item vertically from said carousel to said first conveying apparatus, said carousel being rotatable about a vertical axis to present said item for access by said second conveying apparatus, wherein said first conveying apparatus is configured to convey said item internally within said boom.
 6. A boom as claimed in claim 5 wherein said first conveying apparatus comprises at least one shuttle equipped with a clamp to releasably hold said item, said shuttle running along a track extending along said boom.
 7. A boom as claimed in claim 6 wherein said boom comprises a foldable boom, said foldable boom at least one of: a. being foldable about at least one folding axis, said foldable boom being locatable in a folded stowed position, and moveable to unfolded extended positions; and, b. having a first boom element and a second boom element pivotable about the folding axis spaced from said first horizontal axis, and parallel therewith.
 8. A boom as claimed in claim 7 wherein at least one of: a. each of the first boom element and the second boom element has a track and at least one said shuttle, and each said shuttle is confined for movement along said track within its boom element; and, b. at least one of said first boom element and said second boom element, comprises a plurality of elements arranged in telescoping interconnection.
 9. A boom as claimed in claim 8 wherein said first conveying apparatus is configured to convey said item internally within said boom.
 10. A boom as claimed in claim 7 wherein said first conveying apparatus is configured to convey said item internally within said boom.
 11. A boom as claimed in claim 6 wherein said first conveying apparatus is configured to convey said item internally within said boom.
 12. A boom as claimed in claim 5 wherein said boom comprises a foldable boom, said foldable boom at least one of: a. being foldable about at least one folding axis, said foldable boom being locatable in a folded stowed position, and moveable to unfolded extended positions; and, b. having a first boom element and a second boom element pivotable about the folding axis spaced from said first horizontal axis, and parallel therewith.
 13. A boom as claimed in claim 12 wherein at least one of: a. each of the first boom element and the second boom element has a track and at least one said shuttle, and each said shuttle is confined for movement along said track within its boom element; and, b. at least one of said first boom element and said second boom element, comprises a plurality of elements arranged in telescoping interconnection.
 14. A boom as claimed in claim 13 wherein said first conveying apparatus is configured to convey said item internally within said boom.
 15. A boom as claimed in claim 12 wherein said first conveying apparatus is configured to convey said item internally within said boom. 